Magnetic sensing device including a sense enhancing layer

ABSTRACT

A magnetic sensor includes a sensor stack having a first magnetic portion, a second magnetic portion, and a barrier layer between the first magnetic portion and the second magnetic portion. The first magnetic portion and/or the second magnetic portion comprises a multilayer structure including a first magnetic layer having a positive magnetostriction adjacent to the barrier layer, a second magnetic layer, and an intermediate layer between the first magnetic layer and the second magnetic layer. The magnetic sensor exhibits a magnetoresistive ratio of at least about 62% with a resistance-area (RA) product of about 0.45 Ω·μm 2 .

This application is a continuation-in-part of U.S. application Ser. No. 11/305,778, filed Dec. 16, 2005 by Gao et al. entitled “Magnetic Sensing Device Including A Sense Enhancing Layer”, which issued Sep. 21, 2010 as U.S. Pat. No. 7,800,868. Both the present application and U.S. Pat. No. 7,800,868 are assigned to Seagate Technology LLC.

BACKGROUND

In an electronic data storage and retrieval system, a magnetic recording head typically includes a reader portion having a sensor for retrieving magnetically encoded information stored on a magnetic disc. Magnetic flux from the surface of the disc causes rotation of the magnetization vector of a sensing layer or layers of the sensor, which in turn causes a change in the electrical properties of the sensor. The sensing layers are often called free layers, since the magnetization vectors of the sensing layers are free to rotate in response to external magnetic flux. The change in the electrical properties of the sensor may be detected by passing a current through the sensor and measuring a voltage across the sensor. Depending on the geometry of the device, the sense current may be passed in the plane (CIP) of the layers of the device or perpendicular to the plane (CPP) of the layers of the device. External circuitry then converts the voltage information into an appropriate format and manipulates that information as necessary to recover information encoded on the disc.

A structure in contemporary read heads is a thin film multilayer structure containing ferromagnetic material that exhibits some type of magnetoresistance (MR), such as tunneling magnetoresistance (TMR). A typical TMR sensor configuration includes a multilayered structure formed of an insulating thin film, or barrier layer, positioned between a synthetic antiferromagnet (SAF) and a ferromagnetic free layer, or between two ferromagnetic free layers. The barrier layer is thin enough to allow electron tunneling between the magnetic layers. The tunneling probability of an electron incident on the barrier layer from one magnetic layer depends on the character of the electron wave function and the spin of the electron relative to the magnetization direction in the other magnetic layer. As a result, the resistance of the TMR sensor depends on the relative orientations of the magnetization of the magnetic layers, exhibiting a minimum for a configuration in which the magnetizations of the magnetic layers are parallel and a maximum for a configuration in which the magnetizations of the magnetic layers are anti-parallel.

Some TMR sensors incorporate a barrier layer including magnesium oxide (MgO), which allows for magnetoresistive ratios approaching 200% when the resistance-area (RA) product of the TMR sensor is high (i.e., greater than 10 Ω·μm²). In order to achieve a high magnetoresistive ratio, a CoFeB based single free layer adjacent to the insulating thin film is sometimes used in conjunction with a high temperature anneal (i.e., greater than 300° C.). However, this device results in a high positive magnetostriction, a high RA product, and a high temperature anneal, all of which either reduce performance of the device or make processing of such a device difficult. To reduce the magnetostriction of the device, the CoFeB free layer may be laminated or co-sputtered with a material having a negative magnetostriction. While this results in a sensor having low magnetostriction, the magnetoresistive ratio of the sensor is significantly reduced.

SUMMARY

The present invention relates to a magnetic sensor including a sensor stack having a first magnetic portion, a second magnetic portion, and a barrier layer between the first magnetic portion and the second magnetic portion. The first magnetic portion and/or the second magnetic portion comprises a multilayer structure including a first magnetic layer having a positive magnetostriction adjacent to the barrier layer, a second magnetic layer, and an intermediate layer between the first magnetic layer and the second magnetic layer. The magnetic sensor exhibits a magnetoresistive ratio of at least about 62% with a resistance-area (RA) product of about 0.45 Ω·μm².

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a layer diagram of a magnetic sensor including a multilayer free layer having a sense enhancing layer.

FIG. 2 is a layer diagram of a magnetic sensor including a multilayer reference layer having a sense enhancing layer.

FIG. 3 is a layer diagram of a magnetic sensor including a multilayer free layer having a sense enhancing layer and a multilayer reference layer having a sense enhancing layer.

FIG. 4 is a flow diagram illustrating a process for fabricating a magnetic sensor as described with regard to FIGS. 1-3.

FIG. 5 is a graph of the graph of the resistance-area (RA) product versus magnetoresistive (MR) ratio comparing magnetic sensors fabricated with and without a heating layers before, during, and/or after deposition.

DETAILED DESCRIPTION

FIG. 1 is a layer diagram of a magnetic sensor 10, which includes free layer 14, barrier layer 16, reference layer 18, coupling layer 19, pinned layer 20, and pinning layer 21. Free layer 14 includes first ferromagnetic layer 22, sense enhancing layer 24, and second ferromagnetic layer 26. In some embodiments, magnetic sensor 10 is positioned between two electrodes or shields in a magnetic recording head. Magnetic sensor 10 may also include additional layers, such as a seed layer to promote growth of subsequent layers in magnetic sensor 10, and a cap layer to vary properties of magnetic sensor 10 such as resistance-area (RA) product and magnetoresistive (MR) ratio. It should be noted that the configuration of magnetic sensor 10 is merely illustrative, and other layer configurations for magnetic sensor 10 may be used in accordance with the present invention. For example, a second free layer may be substituted for reference layer 18 to form a tri-layer type magnetic sensor. In addition, while a bottom type sensor configuration is depicted in FIG. 1, the layers of magnetic sensor 10 may also be configured in a top type sensor configuration, or a tri-layer configuration without pinned layer 20 and pinning layer 21.

In operation, a sense current is passed through magnetic sensor 10. The sense current flows perpendicularly to the plane of the layers of magnetic sensor 10 and experiences a resistance that is proportional to the cosine of an angle formed between the magnetization direction of the free layer and the magnetization direction of the reference layer, or between the magnetization direction of the two free layers (in a tri-layer magnetic sensor). The voltage across the magnetic sensor 10 is then measured to determine the change in resistance and the resulting signal is used, for example, to recover the encoded information from a magnetic medium.

Free layer 14 includes first ferromagnetic layer 22, sense enhancing layer 24, and second ferromagnetic layer 26. The magnetization of free layer 14 rotates freely in response to an external magnetic field, such as a field emanating from a magnetic medium. First ferromagnetic layer 22 is positioned adjacent to barrier layer 16, and sense enhancing layer 24 is positioned between first ferromagnetic layer 22 and second ferromagnetic layer 26. First ferromagnetic layer 22 includes a material having a positive magnetostriction, such as CoFeB or CoFe based alloys, to improve the magnetoresistive ratio of magnetic sensor 10 at high (i.e., greater than 10 Ω·μm²) and low (i.e., less than 4 Ω·μm²) sensor resistance-area (RA) products. The ratios of each element in first ferromagnetic layer 22 may be adjusted to improve performance of magnetic sensor 10.

In order to offset the positive magnetostriction of first ferromagnetic layer 22, second ferromagnetic layer 26 is included in free layer 14 on a side opposite of sense enhancing layer 24 from first ferromagnetic material 22. Second ferromagnetic layer 26 includes a material having a negative magnetostriction and may include crystalline or amorphous ferromagnetic materials that exchange couple with first ferromagnetic layer 22. In one embodiment, second ferromagnetic layer 26 includes Ni, Ni based alloys such as NiFe, or CoFe. Second ferromagnetic layer 26 may be laminated or co-sputtered with first ferromagnetic layer 22.

Sense enhancing layer 24 is positioned between first ferromagnetic layer 22 and second ferromagnetic layer 26. Sense enhancing layer 24 significantly improves the magnetoresistive (MR) ratio of magnetic sensor 10 compared to sensors without sense enhancing layer 24. This may be because sense enhancing layer 24 separates crystalline growth of first ferromagnetic layer 22 and second ferromagnetic layer 26, preserves the interface between first magnetic layer 22 and barrier layer 16 and between first ferromagnetic layer 22 and second ferromagnetic layer 26, or prevents diffusion of component elements between first ferromagnetic layer 22 and second ferromagnetic layer 26 (thus preventing degradation of these layers).

In one embodiment, sense enhancing layer 24 is made of Ta. Sense enhancing layer 24 may also be made of other non-magnetic materials such as Ru, Zr, Hf, Nb, Mo, W, Pt, Rh, Ir, Al, Cu, Cr, Ti, or alloys thereof. In one embodiment, the thickness t_(S1) of non-magnetic sensing enhancing layer 24 is in the range of about 0.5 Å to about 10 Å. Sense enhancing layer 24 may also include magnetic materials such as CoZrNb, CoZrTa, FeTa, FeTaN, NiFeZr, CoFeTa, CoNb, or alloys thereof. If sense enhancing layer 24 is made of a magnetic material, thickness t_(S1) may be much greater than if sense enhancing layer 24 is made of a non-magnetic material.

The relative orientations of the magnetizations of first ferromagnetic layer 22 and second ferromagnetic layer 26 depend on the material and thickness of sense enhancing layer 24. That is, first ferromagnetic layer 22 and second ferromagnetic layer 26 may be ferromagnetically coupled, such that the magnetizations of the layers are aligned parallel to each other. First ferromagnetic layer 22 and second ferromagnetic layer 26 may also be antiferromagnetically coupled, such that the layers are aligned antiparallel to each other (e.g., when sense enhancing layer 26 is made of Ru and has a thickness in the range of about 4 Å to about 12 Å).

Barrier layer 16 is made of a material that permits electron tunneling between free layer 14 and reference layer 18. In one embodiment, barrier layer 16 is a layer of magnesium oxide (MgO). The MgO layer may be formed by MgO radio frequency (RF) deposition techniques or molecular beam epitaxy (MBE). The MgO layer could also be formed by oxidizing a deposited Mg layer (such as through plasma oxidation, radical oxidation, or natural oxidation). Barrier layer 16 may also include other structures, such as a Mg/MgO or MgO/Mg bilayer, a Mg/MgO/Mg trilayer, or any other laminated or multilayer structure including MgO and Mg. The thickness of barrier layer 16 is selected to balance maximizing MR ratio and minimizing the RA product of magnetic sensor 10.

Reference layer 18 comprises a ferromagnetic material, such as CoFeB. Reference layer 18 may also be made of any other type of ferromagnetic materials, including crystalline or amorphous ferromagnetic materials. Reference layer 18, coupling layer 19, and pinned layer 20 may comprise a synthetic antiferromagnet (SAF) having a fixed magnetization direction. Reference layer 18 and pinned layer 20 are antiferromagnetically coupled by coupling layer 19 such that the magnetization direction of reference layer 18 is opposite to the magnetization direction of pinned layer 20. Coupling layer 19 may include Ru, Ir, Os, and may have a thickness in the range of about 3 Å to about 10 Å, and more specifically in the range of about 4 Å to about 5 Å. The magnetization of pinned layer 20 is pinned by exchange coupling pinning layer 21 with pinned layer 20. In some embodiments, pinned layer 20 comprises a ferromagnetic material and pinning layer 21 comprises an antiferromagnetic material. Alternatively, the SAF and pinning layer 21 may replaced by a single ferromagnetic layer having a magnetization fixed via a biasing field produced by, for example, permanent magnets (not shown) positioned adjacent to magnetic sensor 10.

FIG. 2 is a layer diagram of magnetic sensor 30, which includes free layer 34, barrier layer 36, reference layer 38, coupling layer 39, pinned layer 40, and pinning layer 41. Reference layer 38 includes first ferromagnetic layer 42, sense enhancing layer 44, and second ferromagnetic layer 46. In one embodiment, magnetic sensor 30 is positioned between two electrodes or shields in a magnetic recording head. Magnetic sensor 30 includes elements having similar properties as like elements in magnetic sensor 10 shown in FIG. 1. In particular, barrier layer 36, coupling layer 39, pinned layer 40, and pinning layer 41 have properties similar to barrier layer 16, coupling layer 19, pinned layer 20, and pinning layer 21, respectively, as described with regard to FIG. 1.

Free layer 34 may be a single layer of ferromagnetic material having a magnetization that rotates freely in response to an external magnetic field, such as a field emanating from a magnetic medium. In some embodiments, free layer 34 is made of CoFeB or CoFe based alloys. Alternatively, free layer 34 may be a bilayer of ferromagnetic layers such as CoFeB (adjacent to barrier layer 36) co-sputtered or laminated with Ni, a Ni based alloy, or other crystalline or amorphous ferromagnetic materials.

Reference layer 38, coupling layer 39, and pinned layer 40 comprise a SAF having a fixed magnetization direction. Reference layer 38 and pinned layer 40 are antiferromagnetically coupled by coupling layer 39 such that the magnetization direction of reference layer 38 is opposite to the magnetization direction of pinned layer 40. Coupling layer 39 may include Ru, Ir, or Os, and may have a thickness in the range of about 3 Å to about 10 Å, and more specifically in the range of about 4 Å to about 5 Å. The magnetization of pinned layer 40 is pinned by exchange coupling pinning layer 41 with pinned layer 40.

Reference layer 38 includes first ferromagnetic layer 42, sense enhancing layer 44, and second ferromagnetic layer 46. First ferromagnetic layer 42 is positioned adjacent to barrier layer 36, and sense enhancing layer 44 is positioned between first ferromagnetic layer 42 and second ferromagnetic layer 46. First ferromagnetic layer 42 may include crystalline or amorphous ferromagnetic materials, such as CoFeB or CoFe based alloys, to improve the magnetoresistive ratio of magnetic sensor 30 at high and low sensor RA products. The ratios of each element in first ferromagnetic layer 42 may be adjusted to improve performance of magnetic sensor 30.

Second ferromagnetic layer 46 of reference layer 38 is positioned on a side opposite of sense enhancing layer 44 from first ferromagnetic material 42. Second ferromagnetic layer 46 may include any crystalline or amorphous ferromagnetic materials that exchange couple with first ferromagnetic layer 42 and have good coupling with pinned layer 40 and pinning layer 41.

Sense enhancing layer 44 is positioned between first ferromagnetic layer 42 and second ferromagnetic layer 46. Sense enhancing layer 44 significantly improves the MR ratio of magnetic sensor 30 compared to sensors without sense enhancing layer 44. In some embodiments, sense enhancing layer 44 is made of Ta. Sense enhancing layer 44 may also be made of other non-magnetic materials such as Ru, Zr, Hf, Nb, Mo, W, Pt, Rh, Ir, Al, Cu, Cr, Ti, or alloys thereof. In some embodiments, the thickness t_(s2) of non-magnetic sensing enhancing layer 44 is in the range of about 0.5 Å to about 10 Å. Sense enhancing layer 44 may also include magnetic materials such as CoZrNb, CoZrTa, FeTa, FeTaN, NiFeZr, CoFeTa, CoNb, or alloys thereof. If sense enhancing layer 44 is made of a magnetic material, thickness t_(S2) may be much greater than if sense enhancing layer 44 is made of a non-magnetic material.

FIG. 3 is a layer diagram of a magnetic sensor 50, which includes free layer 54, barrier layer 56, reference layer 58, coupling layer 59, pinned layer 60, and pinning layer 61. Free layer 54 includes first ferromagnetic layer 62, sense enhancing layer 64, and second ferromagnetic layer 66. Reference layer 58 includes first ferromagnetic layer 72, sense enhancing layer 74, and second ferromagnetic layer 76. In one embodiment, magnetic sensor 50 is positioned between two electrodes or shields in a magnetic recording head. Magnetic sensor 50 includes elements having similar properties as like elements in magnetic sensor 10 shown in FIG. 1. In particular, barrier layer 56, coupling layer 59, pinned layer 60, and pinning layer 61 have properties similar to barrier layer 16, coupling layer 19, pinned layer 20, and pinning layer 21, respectively, as described with regard to FIG. 1.

Free layer 54 has similar configuration and properties to free layer 14 in FIG. 1. Free layer 54 includes first ferromagnetic layer 62, sense enhancing layer 64, and second ferromagnetic layer 66. The magnetization of free layer 54 rotates freely in response to an external magnetic field, such as a field emanating from a magnetic medium. First ferromagnetic layer 62 is positioned adjacent to barrier layer 56, and sense enhancing layer 64 is positioned between first ferromagnetic layer 62 and second ferromagnetic layer 66. First ferromagnetic layer 62 includes a material having a positive magnetostriction, such as CoFeB or CoFe based alloys, to improve the magnetoresistive ratio of magnetic sensor 50 at high and low sensor resistance-area (RA) products. The ratios of each element in first ferromagnetic layer 62 may be adjusted to improve performance of magnetic sensor 50.

Second ferromagnetic layer 66 is made of a material having a negative magnetostriction and is included in free layer 54 on a side opposite of sense enhancing layer 64 from first ferromagnetic material 62. Second ferromagnetic layer 66 may include crystalline or amorphous ferromagnetic materials that exchange couple with first ferromagnetic layer 62. In one embodiment, second ferromagnetic layer 66 includes Ni, Ni based alloys such as NiFe, or CoFe. Second ferromagnetic layer 66 may be laminated or co-sputtered with first ferromagnetic layer 62.

Sense enhancing layer 64 is positioned between first ferromagnetic layer 62 and second ferromagnetic layer 66. Sense enhancing layer 64 significantly improves the MR ratio of magnetic sensor 50 compared to sensors without sense enhancing layer 64 (as will be described in more detail with regard to FIG. 4). In some embodiments, sense enhancing layer 64 is made of Ta. Sense enhancing layer 64 may also be made of other non-magnetic materials such as Ru, Zr, Hf, Nb, Mo, W, Pt, Rh, Ir, Al, Cu, Cr, Ti, or alloys thereof. In some embodiments, the thickness t_(S3) of non-magnetic sensing enhancing layer 64 is in the range of about 0.5 to about 10 Å. Sense enhancing layer 64 may also include magnetic materials such as CoZrNb, CoZrTa, FeTa, FeTaN, NiFeZr, CoFeTa, CoNb, or alloys thereof. If sense enhancing layer 64 is made of a magnetic material, thickness t_(S3) may be much greater than if sense enhancing layer 64 is made of a non-magnetic material.

The relative orientations of the magnetizations of first ferromagnetic layer 62 and second ferromagnetic layer 66 depend on the material and thickness of sense enhancing layer 64. That is, first ferromagnetic layer 62 and second ferromagnetic layer 66 may be ferromagnetically coupled, such that the magnetizations of the layers are aligned parallel to each other. First ferromagnetic layer 62 and second ferromagnetic layer 66 may also be antiferromagnetically coupled, such that the layers are aligned antiparallel to each other (e.g., when sense enhancing layer 66 is made of Ru and has a thickness in the range of about 4 Å to about 12 Å).

Reference layer 58, coupling layer 59, and pinned layer 60 comprise a SAF having a fixed magnetization direction. Reference layer 58 and pinned layer 60 are magnetically coupled by coupling layer 59 such that the magnetization direction of reference layer 58 is opposite to the magnetization direction of pinned layer 60. Coupling layer 59 may include Ru, Ir, or Os, and may have a thickness in the range of about 3 Å to about 10 Å, and more specifically in the range of about 4 Å to about 5 Å. The magnetization of pinned layer 60 is pinned by exchange coupling pinning layer 61 with pinned layer 60.

Reference layer 58 has similar configuration and properties to reference layer 18 in FIG. 1. Reference layer 58 includes first ferromagnetic layer 72, sense enhancing layer 74, and second ferromagnetic layer 76. First ferromagnetic layer 72 is positioned adjacent to barrier layer 56, and sense enhancing layer 74 is positioned between first ferromagnetic layer 72 and second ferromagnetic layer 76. First ferromagnetic layer 72 may include a material having a positive magnetostriction, such as CoFeB or CoFe based alloys, to improve the magnetoresistive ratio of magnetic sensor 50 at high and low sensor RA products. The ratios of each element in first ferromagnetic layer 72 may be adjusted to improve performance of magnetic sensor 50.

Second ferromagnetic layer 76 is positioned in reference layer 58 on a side opposite of sense enhancing layer 74 from first ferromagnetic material 72. The magnetostriction of reference layer 38 may be positive or negative. Thus, second ferromagnetic layer 76 may include crystalline or amorphous ferromagnetic materials that exchange couple with second ferromagnetic layer 76 and have good coupling with pinned layer 60 and pinning layer 61.

Sense enhancing layer 74 is positioned between first ferromagnetic layer 72 and second ferromagnetic layer 76. Sense enhancing layer 74 significantly improves the MR ratio of magnetic sensor 50 compared to sensors without sense enhancing layer 74 (as will be described in more detail with regard to FIG. 4). In one embodiment, sense enhancing layer 74 is made of Ta. Sense enhancing layer 74 may also be made of other non-magnetic materials such as Ru, Zr, Hf, Nb, Mo, W, Pt, Rh, Ir, Al, Cu, Cr, Ti, or alloys thereof. In one embodiment, the thickness t_(S4) of non-magnetic sensing enhancing layer 74 is in the range of about 0.5 to about 10 Å. Sense enhancing layer 74 may also include magnetic materials such as CoZrNb, CoZrTa, FeTa, FeTaN, NiFeZr, CoFeTa, CoNb, or alloys thereof. If sense enhancing layer 74 is made of a magnetic material, thickness t_(S4) may be much greater than if sense enhancing layer 74 is made of a non-magnetic material.

The MR ratio and breakdown voltage of each of the magnetic sensors shown in FIGS. 1-3 may be improved by promoting strong growth texturing and improving the quality of the interface between the barrier layer and adjacent layers in the sensor stack. One approach to accomplishing this is to heat the barrier layer interfaces during the fabrication process. FIG. 4 is a flow diagram of a process for fabricating any of the magnetic sensors 10, 30, or 50 described above using a heated barrier process. To begin, a first magnetic portion is deposited on a substrate (step 70). For example, in magnetic sensor 10, the first magnetic portion may include reference layer 18, coupling layer 19, pinned layer 20, and pinning layer 21. In magnetic sensor 30, the first magnetic portion may include reference layer 38, coupling layer 39, pinned layer 40, and pinning layer 41. In magnetic sensor 50, the first magnetic portion may include reference layer 58, coupling layer 59, pinned layer 60, and pinning layer 61. In some embodiments, the first magnetic portion is deposited directly on a substrate or on a seed layer formed on the substrate.

The first magnetic portion is then heat treated such that at least a top surface of the first magnetic portion is heated (step 72). The heating of the first magnetic portion is carried out in-situ and may be performed in a vacuum environment by heating the substrate on which the first magnetic portion is deposited (to heat the top surface by induction through the layers) or by heating the structure with a heat lamp or other heat source. The top surface of the first magnetic portion is heated to a temperature that provides a template on which the barrier layer is subsequently formed by promoting surface electron mobility. At the same time, the temperature to which the top surface is heated is low enough to avoid inducing roughness or recrystallization of the first magnetic portion. In some embodiments, the top surface of the first magnetic portion is heated to a temperature of between about 80° C. and about 250° C., and more particularly between about 100° C. and about 150° C.

The barrier layer in the magnetic sensor is then deposited on the heated top surface of the first magnetic portion (step 74). For example, this may be barrier layer 16 of magnetic sensor 10, barrier layer 36 of magnetic sensor 30, or barrier layer 56 of magnetic sensor 50. When the barrier layer is deposited on the top surface of the first magnetic portion that has been heated as described above, growth texturing and surface electron mobility are promoted at the interface between the first magnetic portion and the barrier layer. This results in a high quality interface between the barrier layer and the first magnetic portion, barrier growth having a high crystallinity, and less mixing of elements occurs at the interface between the barrier layer and adjacent layers, all of which contributes to improved MR ratio and breakdown voltage characteristics.

The barrier layer may be heated while being deposited on the first magnetic portion (step 76) to further promote surface electron mobility. In some embodiments, a portion of the barrier layer is heated, while in other embodiments, the entire barrier layer is heated. The barrier layer may be heated to a temperature of between about 80° C. and about 250° C., and more particularly between about 100° C. and about 150° C.

A second magnetic portion is then formed on the barrier layer (step 78). For example, the second magnetic portion may include free layer 14 in magnetic sensor 10, free layer 34 in magnetic sensor 30, or free layer 54 in magnetic sensor 50. The entire magnetic sensor may then be annealed with a low temperature anneal (i.e., approximately 250° C.) or a high temperature anneal (i.e., approximately 300° C.) in a magnetic field.

The resulting device is thermally stable up to at least 300° C. In addition, sensors fabricated as described have demonstrated a significantly higher breakdown voltage than devices fabricated with a heated barrier layer. For example, tested devices have achieved breakdown voltages of about 650 mV when the RA product is about 1.5 Ω·μm². Furthermore, magnetic sensors fabricated with some or all of the layer heating processes described above demonstrate significantly improved MR ratios at lower RA products compared with corresponding devices that are fabricated without heating portions of the sensor during fabrication.

FIG. 5 is a graph of the RA product versus MR ratio for two magnetic sensors. Line 90 is a plot of the RA product versus MR ratio of a magnetic sensor fabricated with layers of the sensor heated before, during, and/or after the fabrication process. For comparison, line 92 is a plot of the RA product versus MR ratio of a magnetic sensor fabricated without any heating during the fabrication process. The magnetic sensor fabricated with the heating process exhibits an MR ratio of at least about 62% and has an RA product of about 0.45 Ω·μm², at least about 83% and has an RA product of about 0.6 Ω·μm², and at least about 100% and has a resistance area (RA) product of about 1.0 Ω·μm². Compared to the device fabricated without heating any portions of the device before, during, and/or after fabrication, this is about a 120% increase in MR ratio at an RA product of about 0.45 Ω·μm², about an 80% increase in MR ratio at an RA product of about 0.6 Ω·μm², and about a 25% increase in MR ratio at an RA product of about 1.0 Ω·μm².

In summary, the present invention relates to a magnetic sensor including a sensor stack having a first magnetic portion, a second magnetic portion, and a barrier layer between the first magnetic portion and the second magnetic portion. At least one of the first magnetic portion and the second magnetic portion includes a multilayer structure having a first magnetic layer having a positive magnetostriction adjacent to the barrier layer, a second magnetic layer, and an intermediate layer between the first magnetic layer and the second magnetic layer. The magnetic sensor exhibits an MR ratio of at least about 62% with a resistance area (RA) product of about 0.45 Ω·μm². Magnetic sensors according to the present invention may be fabricated using a low temperature anneal, are thermally stable beyond 300° C., have a negative magnetostriction, have a high breakdown voltage, and demonstrate high MR ratios at low sensor RA products.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. For example, while the magnetic sensors according to the present invention have been described in the context of magnetic recording head applications, it will be appreciated that the magnetic sensors may be used in a variety of other applications, including magnetic random access memory applications. 

1. A method for forming a magnetic sensor, the method comprising: depositing a first magnetic portion; heating at least a top surface of the first magnetic portion; depositing a barrier layer on the heated top surface of the first magnetic portion; and depositing a second magnetic portion on the barrier layer, wherein at least one of the first magnetic portion and the second magnetic portion comprises a multilayer structure including a first magnetic layer having a positive magnetostriction adjacent to the barrier layer, a second magnetic layer, and an intermediate layer between the first magnetic layer and the second magnetic layer.
 2. The method of claim 1, and further comprising: heating the top surface of the first magnetic portion while depositing the barrier layer to a temperature of between about 80° C. and about 250° C.
 3. The method of claim 1, wherein the top surface of the first magnetic portion is heated to a temperature of between about 100° C. and about 150° C.
 4. The method of claim 1, wherein the intermediate layer comprises a material selected from the group consisting of Ta, Ru, Zr, Hf, Nb, Mo, W, Pt, Rh, Ir, Al, Cu, Cr, Ti, CoZrNb, CoZrTa, FeTa, FeTaN, NiFeZr, CoFeTa, CoNb, and alloys thereof.
 5. The method of claim 1, wherein the intermediate layer comprises a non-magnetic material and has a thickness in a range of about 0.5 Å to about 10 Å.
 6. The method of claim 1, wherein the barrier layer comprises a material selected from the group consisting of MgO and Mg.
 7. A method for forming a magnetic sensor, the method comprising: depositing a first magnetic portion; preconditioning the first magnetic portion to promote surface electron mobility at a top surface of the first magnetic portion, wherein preconditioning the first magnetic portion comprises heating the top surface of the first magnetic portion; depositing a barrier layer on the heated top surface of the first magnetic portion; and depositing a second magnetic portion on the barrier layer, wherein at least one of the first magnetic portion and the second magnetic portion comprises a multilayer structure including a first magnetic layer having a positive magnetostriction adjacent to the barrier layer, a second magnetic layer, and an intermediate layer between the first magnetic layer and the second magnetic layer.
 8. The method of claim 7, wherein preconditioning the first magnetic portion comprises heating the top surface of the first magnetic portion to a temperature of between about 80° C. and about 250° C.
 9. The method of claim 8, wherein the top surface of the first magnetic portion is heated to a temperature of between about 100° C. and about 150° C.
 10. The method of claim 7, and further comprising: heating the top surface of the first magnetic portion while depositing the barrier layer.
 11. The method of claim 7, wherein the intermediate layer comprises a material selected from the group consisting of Ta, Ru, Zr, Hf, Nb, Mo, W, Pt, Rh, Ir, Al, Cu, Cr, Ti, CoZrNb, CoZrTa, FeTa, FeTaN, NiFeZr, CoFeTa, CoNb, and alloys thereof.
 12. The method of claim 7, wherein the barrier layer comprises a material selected from the group consisting of MgO and Mg. 